Method for producing prefabricated structural parts

ABSTRACT

The invention relates to a method for producing prefabricated structural parts ( 5, 14 ) from a setting plastic compound for erecting buildings, in which the setting compound is filled into a shuttering and left to set into panels, two panels ( 12, 13 ) being joined together if necessary by means of reinforcements placed into the shutterings to form a double-walled panel ( 14 ). The built-in parts ( 3, 4, 20, 20′ ), which serve for the adjustable support of the prefabricated structural parts and/or for joining them to one another, are attached to the edge regions of the panels or double-walled panels, wherein the built-in parts ( 3, 11, 11′, 20, 20′ ) have fitting portions ( 8, 10, 21, 23 ), which serve as adjusting and joining points with respect to neighbouring panels or double-walled panels. In a further method step, the fitting portions are worked at positions that are fixed with respect to the panels or double-walled panels, in order to compensate for deviations in the position of the fitting portions from the intended dimensions of the panels or double-walled panels. The invention also relates to prefabricated structural parts produced by the method.

TECHNICAL FIELD

The invention relates to a method of making prefabricated structural components as set forth in the preamble of claim 1. In addition, the invention relates to prefabricated structural components in the form of plates or double-walled plates as set forth in the preambles of claims 5 and 7.

PRIOR ART

In known methods of this type, a hardenable plastic material is poured into reusable formworks and allowed to cure. Two of these plates are joined by reinforcement elements to produce double-walled prefabricated structural components.

When structural components of this type are used to erect buildings, the structural components are installed on site on previously produced bottom plates or completed building ceilings, and the intermediate space between the plates of the double-walled prefabricated components is filled with a hardenable plastic material.

Producing the bottom plate requires prior working procedures that are very costly. In addition, a precise bottom plate can be produced only with great difficulty. There is also a further problem if watertight building components are required as otherwise water can penetrate through the construction joint between the bottom plate and the wall plate.

Another disadvantage results from the fact that the alignment of the structural components at the construction site entails very significant cost and effort, and also a corresponding cost and effort to support the structural components in order to retain them in the desired position. This requires several workers and a corresponding input in time, which means higher construction costs.

DESCRIPTION OF THE INVENTION

The object of this invention is to avoid these disadvantages and to propose a method of the type described above where prefabricated structural components can be produced that do not have a construction joint between the bottom plate and the wall plate, that enables a precise bottom plate to be produced where no essential prior work procedures are required to produce the bottom plate, and where simple installation of the produced structural components is made possible at the construction site, thereby significantly reducing the cost of erecting the prefabricated-component building and significantly enhancing the quality of construction.

This is achieved according to the invention in a method of the type mentioned above by the characterizing features of claim 1.

Shaping the parts is done after the mounting fittings have been installed in the plates or double-walled plates under controlled workshop conditions so as to ensure a corresponding precision for the parts. After all of the shapable parts have been aligned to eliminate any deviations in their positions relative to the intended dimensions of the plates, the plates or double-walled plates can be joined with especially tight tolerances during installation.

The plates are advantageously measured by laser and the parts of the mounting fittings are shaped according to plan by a computer-controlled machine tool. This enables a very high degree of accuracy to be achieved.

During installation, the prefabricated structural components are brought into contact with each other by the parts of the corresponding mounting fittings, whereby the plates are automatically aligned in the correct position, then attached to each other by bolts and thus secured in this position, with the result that the individual structural components no longer have to be erected individually. After the structural components have been secured in place as in the prior art, they then only need to be filled with the hardenable plastic material.

It is advantageous to provide the features of claim 2 in order to enable the parts to be easily and rapidly shaped.

It is advantageous to provide the features of claim 3 in order to determine the mutual position of the prefabricated structural components relative to each other.

In addition, the object of the invention is achieved by the prefabricated structural components having the characterizing features of claims 5 and 7. The features of claim 5 here enable the plates to be provided as bottom plates that are simple to move into the correct position on the base by adjusting their height. It is not necessary to lay a complete foundation but instead only to set individual selective support surfaces for the supporting elements that are then adjusted for height.

It is advantageous to provide the features of claim 6 in order to ensure that the bottom plates are easily and reliably attached to the other bottom plates.

The features of claim 7 provide the advantage of producing a vertical wall that can be easily attached to other structural components without further adjustment.

BRIEF DESCRIPTION OF THE DRAWING

The following describes the invention in more detail with reference to the drawing, in which:

FIG. 1 schematically illustrates one portion of a building in the process of being constructed using prefabricated structural components according to the invention;

FIG. 2 is a schematic top view showing the attachment of two bottom plates;

FIG. 3 schematically illustrates the attachment of a bottom plate to a prefabricated structural component forming a wall;

FIG. 4 is side view of the attachment shown in FIG. 2.

WAYS OF CARRYING OUT THE INVENTION

When a building is being constructed, spot foundations 1 are made in a subsoil 2. These foundations 1 support height-adjustable mounting fittings 3, 4 that are attached to a prefabricated structural component 5 in the form of a bottom plate. These are advantageously made in a reusable formwork for the manufacture of such prefabricated structural components 5. Anchors 6 of the mounting fittings 3, 4 here are surrounded by the hardenable plastic material from which prefabricated structural components 5 are produced, and thus are anchored therein.

The prefabricated structural components 5 that function as bottom plates can be aligned horizontally by adjusting bolts or devices 7, 7′.

The mounting fittings 3 furthermore include parts 8 that are made of plastic and extend across the edges of an opening 9 and are preferably molded onto the mounting fitting 3 as blanks. After the parts 8 have been measured and shaped to align the position relative to the plates, the parts 8 have essentially frustoconical alignment surfaces. These surfaces interact with or engage complementary alignment surfaces of additional parts 10. The parts 10 are retained here in mounting fittings 11 that attach two plates 12, 13 of a wall or double-walled prefabricated structural component 14 to each other.

Attachment of prefabricated structural components 5 to the wall or double-walled prefabricated structural components 14, which are aligned vertically and function as a vertical walls, is done by bolts 15 and nuts 16, the bolts 15 passing through drilled holes in the parts 8 and 10. As shown in FIG. 3 in which mounting fittings 3 and 11 are illustrated at a larger scale, locknuts 17 are also provided here.

Anchors 6 fix the mounting fittings 11 in the plates 12, 13.

The space between the plates 12, 13 of the prefabricated structural component 14, and the space between the subsoil 2 and prefabricated structural component 5 that forms the bottom plate, is filled with a hardenable plastic material, such as, e.g. in-situ concrete.

When additional floors are erected, adjustable supports 18 and beams 19 are used to support subsequent prefabricated structural components 5′ and to appropriately align these horizontally. The prefabricated structural components 5′ are attached here to double-walled prefabricated structural components 14. The mounting fittings 11 and 3′ are provided for this purpose, the latter matching the mounting fittings 3 but including locating means for an additional part 8 that interacts with a complementary part 10 that is retained within a mounting fitting 11′ and attaches both of the plates 12, 13 of the double-walled prefabricated structural component 14 to each other.

In-situ concrete or floor pavement can be applied to the prefabricated structural component 5′ that functions as a ceiling.

In order to attach two prefabricated structural component 5, 5′ functioning as a floor or ceiling, mounting fittings 20, 20′ are anchored in these components by the anchors 6. As is shown in FIG. 2, these mounting fittings 20, 20′ are angled and support the parts 8 or 10, and are attached to each other by bolts 15 that project through drilled holes into the mounting fittings 8, 10, and by nuts 16, 17. For best alignment, the parts 8, 10 are provided with the frustoconical mounting surfaces 25.

The mounting fittings 20′ support another mounting fitting 21 that has a groove 22 of triangular cross-section, as shown in FIG. 4, and interacts with another mounting fitting 23 that has complementarily shaped alignment surfaces 24 and is retained in the mounting fitting 11 or 11′ that each attach together two plates 12, 13 of the double-walled prefabricated structural component 14.

The mounting fittings 20 or 20′ can also be provided with adjusting bolts 7, as shown in FIG. 4, so as to provide support on one of spot foundations 1, and thus enable the component 5 to be aligned horizontally.

As shown in FIG. 3, the plate 12 of the double-walled prefabricated structural component 14 functioning as a vertical wall projects essentially over the mounting fittings 3 and terminates just in front of the respective foundation 1 or subsoil 2. This results in only correspondingly small gaps that can easily be sealed before filling the structural components 14 with hardenable plastic material.

As already mentioned above, the parts 8, 10, 21, 23 are molded onto the mounting fittings such that the molded blanks bilaterally fit on both sides of edges of the openings 9 of the mounting fittings 3, 11, 11′, 20, 20′. When prefabricated structural components are produced, these molded blanks are measured and shaped in terms of their intended position relative to the intended dimensions of the plates, thereby creating structural components that can be attached to each other in the intended sequence.

Setting up the building of prefabricated structural components thus only necessitates setting up the bottom plates in their position with the adjusting devices. The following vertically oriented structural components can then be attached to the first structural component to be erected by the respective mounting fittings together with parts and bolts that force them into the correct position. As a result, the cost of assembly at the construction site is very considerably reduced. 

1. A method of making prefabricated structural components from a hardenable plastic material for erecting buildings in which the hardenable material is poured into a formwork and allowed to harden into plates, the method comprising the steps of: installing mounting fittings that function to support the prefabricated structural components and/or to attach them to each other at edges of the plates, the mounting fittings having parts that function as alignment or attachment points for adjacent plates or double-walled plates, and shaping the parts in a further procedural step at positions determined for the plates or double-walled plates so as to compensate for any deviations in the position of the parts relative to the intended dimensions of the plates or double-walled plates.
 2. The method according to claim 1, wherein the parts are made of plastic.
 3. The method according to claim 1, wherein the parts are provided with frustoconical alignment surfaces by milling, or are provided with generally conical alignment surfaces to allow the plates or double-walled plates to be aligned.
 4. The method according to claim 1, wherein molded blanks of the parts are molded onto the mounting fittings, such that the molded blanks fit to both sides of the edge of an opening of the mounting fittings.
 5. A prefabricated structural component in the form of a plate that is produced according to the method of claim 1, wherein the plate is a bottom plate, at least three of the mounting fittings being additionally provided with height-adjustable supporting elements to support the bottom plate against a base.
 6. The prefabricated structural component according to claim 5, wherein the parts of the mounting fittings of the bottom plate are parallel to a plane of the plate for attaching multiple bottom plates one below the other, and in a direction perpendicular to the plate plane for attaching the bottom plate to a double-walled plate in the form of a vertical wall, and that at least two parts are provided per alignment on at least one, preferably each narrow edge face of the bottom plate.
 7. The prefabricated structural component in the form of a double-walled plate that is produced according to the method of claim 1, wherein the double-walled plate is provided in the form of a vertical wall, wherein the parts of the mounting fittings are aligned in the direction of the plate plane for attaching a vertical wall to another vertical wall and/or bottom plate, and that at least two parts each are provided on at least one narrow edge face of the vertical wall. 